Automobile molding member having improved weir structure

ABSTRACT

A novel method of producing molding members for automobiles, formed at least partly of a synthetic resin material is disclosed. According to the method of the invention, synthetic resin material is extrusion molded into a continuous body with a substantially constant cross-section throughout the entire length thereof. A controlled amount of the material is removed from a predetermined location of the continuous body, corresponding to a water flow blocking projection, synchronously with the extrusion molding of the material, such that the cross-section of the continuous body varies in the longitudinal direction of the body. The continuous body subjected to the controlled removal of the material is then cut into the predetermined length of the molding member.

This is a division of application Ser. No. 07/180,893, filed Apr. 13,1988, now U.S. Pat. No. 4,865,796.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a method of producing molding membersfor automobiles, formed at least partly of a synthetic resin material.

2. Description of the Related Art

An automobile employs various kinds of elongate molding members formedat least partly of a synthetic resin material, such as drip moldingmembers, front and rear window molding members, etc. Of these, the dripmolding member extends along the front pillar and the side edge of theroof panel of the vehicle body, while front and rear window moldingmembers extend respectively along the periphery of the front and rearwindow plates, i.e. along the front and rear pillars and the front andrear edges of the roof panel. A variety of requirements are imposed onthe molding members, mainly from design and/or functional viewpoint,resulting in an increased demand in the automobile industry for moldingmembers whose cross-sectional shape varies in the longitudinaldirection.

More particularly, one proposal is directed to a window molding memberhaving side portions with a first predetermined cross-sectional shape,an upper portion with a second predetermined cross-sectional shape, andcorner portions arranged between the side and upper portions, where thecross-sectional shape changes gradually from the first to the second.

Another proposal is directed to a drip molding member composed of a coreelement in the form of a metal strip which has been shaped into thedesired cross-sectional shape, as well as upper and lower lip elementsof synthetic resin material which are integral with the core element andmolded such that the core element is partly exposed to, and visible fromthe outside as a longitudinally extending ornamental portion with ametallic luster. The lower lip element is of a cross-sectional shapethat is substantially constant throughout the entire length, while theupper lip element has a pillar portion with a relatively wide firstcross-sectional shape, a roof portion with a relatively narrow secondcross-sectional shape, and a corner portion between the pillar and roofportions, where the cross-sectional shape changes gradually from thefirst to the second.

To produce elongate molding members whose cross-sectional shape variesin the longitudinal direction, it has been a conventional practice touse a process which includes preparation of the core element by shapingthe raw metal strip into the desired cross-sectional shape with a rollforming machine, press machine, etc., placing each core element in themold of an injection molding machine, and subsequently molding thesynthetic resin material into the desired configuration. With such aprocess, however, since the entire core element of the elongate moldingmember has to be completely accommodated in the mold, the moldingmachine as a whole becomes very bulky and requires a substantial spacein the factory. Moreover, the process involves relatively complex stepswith which the molding members can be produced only one by one, and itis thus difficult to improve the productivity.

Another possibility for the production of such molding members is tophysically divide each molding member into first and second extrudeportions with the respectively predetermined cross-sectional shapes,which are connected with each other either by an injection moldingprocess or by using a separate connection piece. However, connection ofthe two portions by means of the injection molding accompanies formationof undersirable burrs along the junctions and resultant deterioration inthe appearance, while use of the separate connection piece results inthe increased number of the required components and assembly steps.

SUMMARY OF THE INVENTION

Therefore, it is a primary object of the present invention to provide anovel method of producing elongate molding members for automobiles,having a cross-sectional shape which is variable in the longitudinaldirection, in a facilitated manner and with an improve productivity.

According to the present invention, there is provided a method ofproducing molding members for automobiles, which comprises thecombination of the following three steps. The first step is extrusionmolding synthetic resin material into an elongate continuous body with asubstantially constant cross-section throughout the entire length of thecontinuous body. The second step is the removal of a controlled amountof the synthetic resin material from a predetermined location of thecontinuous body. The removal is carried out synchronously with theextrusion molding of the synthetic resin material, in such a manner thatthe cross-section of the continuous body varies in the longitudinaldirection. Finally, in the third step, the continuous body which hasalready been subjected to the removal of the synthetic resin material iscut into a predetermined length of the molding member.

With the above-mentioned method of the present invention, thelongitudinally variable cross-sectional shape of the molding member canbe readily obtained essentially based on extrusion molding technology,simply by removing a controlled amount of the synthetic resin materialfrom a predetermined location of the continuous body after it has beenextruded, and by subsequently cutting the continuous body into apredetermined length of the molding member. According to the presentinvention, all the process steps can be carried out continuously, ascontrasted with the conventional injection molding method, so that it ispossible to produce the molding members with the desired, longitudinallyvariable cross-sectional shape, by means of a compact arrangement of thefacility, and with a markedly improved productivity.

Moreover, connection of separately extruded portions of a moldingmember, either by means of an injection molding process or by aconnection piece, is not necessary, so that the present invention doesnot require the assembly of a plurality of components when producing amolding member, and preserves an excellent appearance of the product inan advantageous manner.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an automobile with molding members whichmay be produced by the method in accordance with the present invention;

FIG. 2 is a side view of a drip molding member shown in FIG. 1;

FIG. 3 is a fragmentary perspective view, in an enlarged scale, of thedrip molding member shown in FIG. 2;

FIG. 4 is a system diagram of the production line for carrying out themethod of the present invention, which is adapted to produce variousmolding members;

FIG. 5 is a side view of the first cutting station as shown in FIG. 4;

FIG. 6 is a sectional view taken substantially along the line A--A inFIG. 5;

FIG. 7 is a diagram showing the relation between the displacement of thecutter member and the supplied length of the core element;

FIGS. 8 and 9 show modifications of the cutting members;

FIG. 10 shows another modified example which is further provided with areforming roller behind the cutter member;

FIG. 11 is a sectional view of the side portion of the window moldingmember, which may be produced by the method in accordance with thepresent invention, and which has been secured to an automobile body;

FIG. 12 is a sectional view of the upper portion of the window moldingmember shown in FIG. 11;

FIG. 13 is a front view of the first cutting station adapted to producethe window molding member shown in FIGS. 11 and 12;

FIG. 14 is a sectional view taken substantially along the line B--B inFIG. 13;

FIG. 15 is a front view similar to FIG. 13, but showing a differentoperational position of the forming roller;

FIG. 16 is a schematic view showing the length of each portion of thewindow molding member;

FIG. 17 is a diagram showing the relation between the displacement ofthe forming roller and the supplied length of the core element;

FIG. 18 is a side view showing the modification to the cutting stationshown in FIGS. 13 and 14;

FIG. 19 is a sectional view of the side portion of another windowmolding member, which may also be produced by the method in accordancewith the present invention;

FIG. 20 is a sectional view of the upper portion of the window moldingmember shown in FIG. 19;

FIG. 21 is a front view of the cutting station which may be used toproduce the window molding member shown in FIGS. 19 and 20;

FIG. 22 is a sectional view of the cutting station taken substantiallyalong the line C--C in FIG. 21;

FIG. 23 is a perspective view of another example of the cutter member;and

FIG. 24 is a sectional view of still another window molding member whichmay also be produced by the method in accordance with the presentinvention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention will now be explained in further detail, byreferring to some preferred embodiments shown in the attached drawings.

There is shown in FIG. 1 an automobile designated as a whole byreference numeral 1, which is provided with various kinds of elongatemolding members composed at least partly of a suitable synthetic resinmaterial. These molding member include, among others, a front windowmolding member 2, a drip molding member 3, etc., and the presentinvention is applicable to produce these elongate molding members withan improved productivity, as will be fully explained hereinafter.

The front window molding member 2 is arranged along the periphery ofside or the windshield plate, and includes a pair of side or pillarportions 2a extending along the front pillars of the automobile 1,respectively, an upper or roof portion 2b extending along the front edgeof the roof panel of the automobile 1, and a pair of corner portions 2carranged between the pillar portions 2a and that roof portion 2b. Eachpillar portion 2a has a predetermined first cross-sectional shape whichis substantially constant throughout the entire length of that portion2a. Similarly, the roof portion 2b has a predetermined secondcross-sectional shape which is substantially constant throughout theentire length of that portion 2b, but which is different from that ofthe pillar portion 2a. Consequently, the shape of the pillar portion 2agradually changes to that of the roof portion 2b in each corner portion2c, or in its neighborhood.

On the other hand, the drip molding member 3 is arranged along the frontpillar and the side edge of the roof panel of the automobile, andincludes a pillar portion 3a of a length L₁, a corner portion 3b of alength L₂ and a roof portion 3c of a length L₃. The drip molding member3 is composed of a core element 4 having an ornamental outer surface 5with a metallic luster, and upper and lower lip elements 6, 7 which arearranged along the upper and lower edges of the core element 4,respectively, in such a manner that the ornamental outer surface 5 ofthe core element 4 is exposed outside between the lip elements 6, 7.

The core element 4 is formed of a metal strip, such as a stainless steelstrip, shaped into a desired cross-section which is substantiallyconstant throughout the entire length of the drip molding member 3. Theupper and lower lip elements 6, 7 are formed of suitable synthetic resinmaterial which has been co-extruded about the core element 4. The lowerlip element 7 has a cross-section which is substantially constantthroughout the entire length of the drip molding member 3, while theupper lip element 6 has a cross-section which varies in the longitudinaldirection of the molding member 3. More particularly, the upper lipelement 6 has a relatively wide and substantially constant cross-sectionalong the pillar portion 3a, a relatively narrow and substantiallyconstant cross-section along the roof portion 3c, and a transitionalcross-section along the corner portion 3b between the pillar and roofportions 3a, 3c in which the wide section changes gradually to thenarrow section.

According to the present invention, the above-mentioned molding members2, 3 can be produced in the manner to be described hereinafter. Just forthe sake of convenience, the following description will be made withreference to the production of the drip molding member 3.

There is shown in FIG. 4 a system diagram of the production line forcarrying out the method according to the present invention. Theproduction line includes an uncoiler 11 from which a metal strip 12 iscontinuously supplied by a pair of pinch rollers 13. Another roller 14serves to continuously supply a protective tape 15 which is separablyadhered, by means of a pair of adhesion rollers 16, onto that portion ofthe metal strip 12 which eventually forms the ornamental portions 5 ofthe molding member 3 with the desired metallic luster, and which hasthus to be protected by the tape 15. The metal strip 12 applied with theprotective tape 15 forms a composite body 17 which, subsequently, issubjected to surface degreasing and cleaning at a cleaning station 18for carrying out a sanding or the like treatment, is coated with anadhesive material at a roll coating station 19, and is subjected tobaking at the baking station 20. The composite body 17 is further passedthrough and cooled in a cooling tank 21, and is then shaped into adesired, longitudinally constant cross-section at a roll forming machine22 to form a continuous core element 4 of the molding member 3.

The core element 4 so obtained is supplied to a measuring station 23which includes a rotary encoder or the like detector for measuring thesupplied length of the core element 4, and then to an extrusion die 24which is further supplied with a suitable synthetic resin material inits heated molten state. The molten synthetic resin material isco-extruded from the extrusion die 24 as a continuous extruded body 25in which the upper and lower lip elements 6, 7 are made integral withthe core element 4, whereby the extruded body 25 has a substantiallyconstant cross-section which corresponds to that of the pillar portion3a of the molding member 3.

To produce molding members with a longitudinally variable cross-section,in accordance with the illustrated preferred embodiment of the presentinvention, the extruded body 25 as extruded from the extrusion die 24 isfurther subjected to the removal of a controlled amount of syntheticresin material from the predetermined location of the upper lip element6. To this end, there is provided a controller 26 which is adapted toreceive from the measuring station 23 a signal representing the suppliedlength of the core element 4, while a first cutting station 27 isarranged on the exit or discharge side of the die 24 and is adapted tobe controlled by the controller 26 according to the supplied length ofthe core element 4. The extruded body 25 is subsequently passed througha cooling tank 28 where it is cooled, and is then advanced by a take-updevice 29 and cut into the predetermined length of the product at asecond cutting station 30 which, too, is controlled by the controller 26according to the supplied length of the core element 4.

As particularly shown in FIGS. 5 and 6, the first cutting station 27includes a support table 31 arranged adjacent to, and on the dischargeside of, the extrusion die 24 for supporting the extruded body 25 as itis extruded from the die 24, a rotatable cutter blade 32 biased towardthe support table 31 by means of a compression coil spring 33, as wellas a slider member 34 for mounting the cutter blade 32 which member ismovable in a direction that extends in parallel with the rotational axisof the cutter blade 32. The slider member 34, per se, is supported by athreaded drive shaft 35 and a stationary guide rod 36 which is fixedlysecured to a pair of brackets 37, 38. The drive shaft 35 is rotatablyjournalled by the brackets 37, 38, is in mesh with the slider member 34,and is connected to a reversible servomotor 39 which is adapted to becontrolled by the controller 26. Thus, by actuating the servomotor 39 inthe normal or reverse direction, the cutter blade 32 is caused to movein the desired axial direction M or N both indicated by double arrow inFIG. 6, in accordance with the length of the core element 4 supplied tothe extrusion die 24.

FIG. 7 shows the relation between the length of the core element 4 whichhas been supplied to the extrusion die 24 and the displacement of thecutter member 32, during the production of the drip molding member 3explained above with reference to FIGS. 2 and 3.

For the period in which the extrusion die 24 discharges that portion ofthe extruded body 25 which corresponds to the pillar portion 3a of themolding member 3 with the length L₁, co-extrusion of the synthetic resinmaterial with the core element 4 is carried out with the cutter member32 maintained at an extreme position in the axial direction M, after theservomotor 39 has been actuated in the normal direction. In this extremeposition, the cutter member 32 is spaced from the upper lip element 6 ofthe molding member 3.

As the detector of the measuring station 23 detects the completion ofthe supply of twice the length L₁ of the core element 4, or thebeginning point of the corner portion 3b of the length L₂, thecontroller 26 supplies a command signal to the servomotor 39. By thisthe servomotor 39 is actuated in the reverse direction, causing thecutter member 32 to move in the axial direction N. During this movement,the cutter member 32 comes into contact with the upper lip portion 6. Asthe cutter member 32 is further moved toward another extreme position inthe axial direction N, until completion of the supply of length L₂ ofthe core element 4, the cutter member 32 removes a desired part 6a ofthe synthetic resin material of the upper lip element 6 with a graduallyincreasing width.

When the detector at the measuring station 23 detects the beginningpoint of the roof portion 3c of the drip molding member 3 with thelength L₃, the servomotor 39 is stopped so that the cutter member 32 ismaintained in its extreme position in which the removal of the syntheticresin material is carried out with the maximum width.

The cutter member 32 is maintained in this extremem position until thedetector of the measuring station 23 detects completion of the supply oftwice the length L₃ of the core element 4. At such occasion, thecontroller 26 supplies a command signal to the servomotor 39 to actuatethe latter in the normal direction. By this, the cutter member 32 iscaused to move in the axial direction M, removing the synthetic resinmaterial from the upper lip element 6 with a gradually decreasing widthuntil the detector of the measuring station 23 detects completion of thesupply of the length L₂ of the core element 4.

Subsequently, the cutter member 32 is disengaged from the lip element 6and is returned to its initial extreme position in the axial directionM. The cutter member 32 is maintained in this position for a new cycleof operation.

Preferably, the removal of the synthetic resin material is carried outwhile the extruded body 25 is still hot and soft.

The extruded body 25 subjected to the removal of the synthetic resinmaterial at the first cutting station 27 is then supplied to the secondcutting station 30 where it is cut into the predetermined length of thedesired molding member 3 at predetermined positions of the extruded body25 which correspond to the centers of the length 2L₁ and 2L₃,respectively.

Furthermore, by repeating the above-mentioned operations, the moldingmembers can be continuously produced one by one, in an efficient andreliable manner.

FIGS. 8 through 10 show various modified embodiments of the firstcutting station 27, the particulars of which will be briefly explainedbelow.

The embodiment shown in FIG. 8 features an arrangement wherein thecutter member is formed of a cutter plate with a sharp edge, which isdisposed on the discharge end wall of the extrusion die 24 and ismovable in the directions P and Q, both indicated by double arrow, so asto provide a longitudinally variable width of that part 6a of thesynthetic resin material of the upper lip element 6, which is to beremoved in accordance with the length of the core element 4 supplied tothe extrusion die 24.

The embodiment shown in FIG. 9 features an arrangement wherein thecutter member 32 is formed of a plate which is movable in the directionsR and S both indicated by double arrow. The cutter blade 32 is so shapedas to define an arcuate blade portion, whereby the cut section of theupper lip element 6 becomes partly arcuate when longitudinally variableamount of the synthetic resin material is removed in accordance with thelength of the core element 4 supplied to the extrusion die 24.

The embodiment shown in FIG. 10 includes a reforming roller 40 arrangedbehind the cutter member 32, which roller is formed with acircumferentially extending reforming groove 41. The reforming roller 40may be combined with any of the above-mentioned cutter members 32, andserves to effectively reform the surface of the molding member 2, 3 withundesirable sharp edges or uneven cut sections, which have been formedas a result of the cutting operation or removal of the synthetic resinmaterial by means of the cutter member 32. To this end, the reformingroller 40 is adapted to be moved in the directions T and U, bothindicated by double arrow, synchronously with the movement of the cuttermember 32 in the axial directions M and N, P and Q, or R and S.

The embodiments thus far described have been directed to an arrangementwherein the removal of the synthetic resin material from the upper lipelement 6 of the drip molding member 3 is effected with respect to thecorner and roof portions 3b, 3c, only. It is, however, possible toremove the material with a relatively small width from the lip element 6along the pillar portion 3a of the molding member 3 as well. Also, thecutter member 32 and/or the second cutting station may effect therespective cutting operation in accordance with the length of theextruded body 25, instead of the supplied length of the core element 4.This is particularly effective for a molding member without the coreelement.

Another embodiment of the present invention, which is applied to theproduction of the window molding member, will now be explained withreference to FIGS. 11 and 12. The molding member to be produced isdesignated as a whole by reference numeral 50, and is adapted to bearranged along the outer periphery of a front or rear window plate 51which is formed of a transparent inorganic glass or transparentsynthetic resin, such as polycarbonate resin, acrylic resin, or thelike. The window plate 51 is secured to the automobile body panel 52 bymeans of an adhesive material 53, with a rubber dam member 54 arrangedbetween the plate 51 and the body panel 52. The window plate 51 isfurther provided, on its rear surface, with an opaque printed layer 55which extends along the periphery of the plate 51 so that the adhesivematerial 53 and the dam member 54 are not visible from outside, whichthus provides a highly refined appearance.

The window molding member 50 includes a main body 56 which is formed offlexible and/or soft polyvinylchloride (PVC) resin, ionomer resin,ethylenevinyl acetate copolymer (EVA) resin, transparent celluloseacetate butylate (CAB) resin, appropriate synthetic rubber material orother suitable thermoplastic and elastomeric synthetic resin materialwith a flexibility. The material forming the main body 56 is extrudedabout a metal strip forming a core element 57 which is thus embedded inthe synthetic resin material of the main body 56.

More particularly, as shown in FIG. 11 illustrating the cross-section ofthe molding member 50 at its side portion when the window plate 51 is afront window plate, the main body 56 of the window molding member 50includes a leg section 58 extending into a gap 59 left between thewindow plate 51 and the automobile body panel 52. The main body 56further includes a pair of lip sections 60, 61 formed on, and projectingfrom both sides of the leg section 58. The lip section 60 has a free endwhich bears against the outer surface of the automobile body panel 52,while the lip section 61 is formed with a projection 62 in the form of aridge near the free end thereof, which bears against the outer surfaceof the window plate 51. The projection 62 cooperates with the free endof the lip section 61 and the window plate 51 to define a channel 63which serves to prevent side flow of the water or rain drops 64 acrossthe front pillar of the automobile, from the front window plate towardthe side window, and effectively preserves the driver's and/ornavigator's sight through the side window, during the driving of theautomobile in rainy climate condition. In other words, the channel 63guides the flow of water or rain drops 64 along the side edge of thefront window plate 51.

The channel 63 thus extends along the front pillar of the automobile,but is not required along the junction between the upper edge of thefront window plate and the roof panel of the automobile; rather,provision of such a channel along the upper edge of the front windowplate is undesirable since the channel prevents realization of theso-called flush outer surface of the automobile. Hence, as particularlyshown in FIG. 12 illustrating the cross-section of the upper portion ofthe molding member 50, the lip section 61 of the main body 56 in itsupper portion is not provided with the projection 62 with a sufficientlength to define the channel 63. Furthermore, the lip section 61 assumesan angular position with reference to the leg section 58, which isdifferent from that shown in FIG. 11, and is in direct contact with thesurface of the window plate 51 as shown in FIG. 12. This means that thewindow molding member 50 shown in FIGS. 11 and 12 has a cross-sectionwhich varies in the longitudinal direction.

The window molding member 50 shown in FIGS. 11 and 12 can be produced bythe method according to the present invention, with a production linewhich is substantially the same as that shown in FIG. 4. The maindifference resides in the arrangement of the first cutting station 27arranged adjacent to the extrusion die 24. According to the presentembodiment, as shown in FIGS. 13 to 15, the first cutting station 27includes a stationary cutter member 65 which assumes a fixed positionwith reference to the extrusion die 24, a forming roller 66 supported bya movable frame 67 and adapted to be brought into contact with the lipsection 61 of the extruded body 25 forming the molding member 50,thereby to deform the lip section 61 while it is still hot and soft. Ascrew threaded rod 68 connects the frame 67 with a reversible servomotor69 which, in turn, is connected to a controller, like the controller 26as shown in FIG. 4. Thus, the servomotor 69 is adapted to displace theforming roller 66 in the direction M' or N' as shown by double arrow inFIGS. 13 and 14, in accordance with the length of the core element 57supplied to the extrusion die 24.

Assuming that, as shown in FIG. 16, the window molding member 50 has apair of side portions 50a, 50b of the length L₁, a pair of cornerportions 50c, 50d of the length L₂ and an upper portion 50e of thelength L₃, the relation between the displacement of the forming roller66 in the directions M' and N' and the supplied length of the coreelement 57 is as shown in FIG. 17.

More particularly, during the period in which the die 24 discharges thatportion of the extruded body 25 which corresponds to the side portions50a, 50b of the molding member 50 with the length L₁, the forming roller66 assumes its uppermost position and is out of contact with the surfaceof the lip section 61, while the cutter member 65 extends slightly intothe projection 62 of the lip section 61 so that a controlled smallamount of material is removed from the projection 62, as shown in FIG.15.

As the detector of the measuring station detects the completion of thesupply of the length L₁ of the core element 57, or the beginning pointof the corner portion 50c of the length L₂, the servomotor 69 isactuated in the normal direction, displacing the forming roller 66 inthe direction N'. During this movement, the forming roller 66 comes intocontact with the lip section 61 to deflect this sectioncounterclockwisely with reference to the leg section 58, from an initialangular position shown in FIG. 15 to a deflected angular position shownin FIG. 13. Such a deflection of the lip section 61 causes theprojection 62 to be lowered, as seen in FIGS. 13 to 15, whereas thecutter member 65 assumes a fixed position with reference to theextrusion die 24, so that the projection 62 is subjected to the removalof the material with a gradually increasing depth.

When the detector at the measuring station detects the completion of thesupply of the length L₂ of the core element 57, or the beginning of theupper portion 50e of the molding member 50 with the length L₃, theservomotor 69 is stopped so that the forming roller 66 is maintained inits lowermost position. The resultant maximum deflection of the lipsection 61 corresponds to the removal of the material from theprojection 62 with the maximum depth.

The forming roller 66 is maintained in this position until the detectorof the measuring station detects completion of the supply of the lengthL₃ of the core element 57. The servomotor 69 is then actuated in thereverse direction to displace the forming roller 66 toward the uppermostposition. The lip section 61 begins to restore into the initial angularposition shown in FIG. 15, and the projection 62 thus moves upwardlywith reference to the cutter member 65, so that the cutter member 65removes material from the projection 62 with a gradually decreasingdepth.

The servomotor 69 is stopped as the detector of the measuring stationdetects completion of the length L₂ of the core element 57, and theforming roller 66 is maintained in its uppermost position shown in FIG.15, for a new cycle of operation, until twice the length L₁ of the coreelement 57 is supplied to the extrusion die 24.

The extruded body 25 is then cooled and solidified, and is furthersupplied to the second cutting station, like the station 30 shown inFIG. 4, where it is cut into the predetermined length of the windowmolding member 50 at a point X shown in FIG. 17, which is at the centerof the two side portions.

A modification to the above-mentioned embodiment is shown in FIG. 18, inwhich the cutter member 70 is arranged on or adjacent to the extrusiondie 24 and is movable in the directions P' and Q', synchronously withthe movement of the forming roller 66 in the directions M' and N'. Thedepth with which material is removed from the projection 62 is varied bythe movement of the cutter member 70, while the forming roller 66 servesto deform the lip section 61 while it is still hot and soft.

The window molding member 50 shown in FIGS. 11 and 12 can be produced ina continuous manner as described above. To arrange the molding member inplace, first of all, a strip-like retainer member 71 with a plurality ofretaining fins is adhered to the side and upper webs 52a of theautomobile body panel 52. The rubber dam 53 is preliminary secured ontothe periphery of the rear surface of the window plate 51 which is thenapplied with adhesive material 53. The window plate 51 is thentemporarily supported on the flange 52b of the body panel 52, and theleg section 58 of the molding member 50 is inserted, before the adhesivematerial 53 hardens, into the gap 59 between the body panel 52 and thewindow plate 51, engaging fins 58a and 58b of the leg section 58 withthe retaining fins of the retainer member 71 and the rear edge of thewindow plate 51, respectively.

Still another embodiment of the present invention, also applied to theproduction of the window molding member, will now be explained withreference to FIGS. 19 and 20. This embodiment differs from that shown inFIGS. 11 and 12 essentially in the cross-sectional shape of the moldingmember, so that same reference numerals are used to denote the same orfunctionally equivalent elements.

The molding member 50 to be produced includes a main body 56 formed ofan appropriate synthetic resin material, a plurality of core elements 57embedded in the main body 56, an ornamental film 72 with a metallicluster or an appropriate color, which is partly exposed outside, a legsection 58 with fins 58a, 58b, which is to be inserted into the gap 59formed between the automobile body panel 52 and the window plate 51, apair of lip sections 60, 61 formed on and projecting from both sides ofthe leg section 58. Along the side portions of the molding member 50, asshown in FIG. 19, the lip section 61 is provided with a projection 62 inthe form of a ridge projecting from that side of the lip section 61which is remote from the window plate 51. In the upper and cornerportions of the molding member 50, as shown in FIG. 20, the syntheticresin material forming the projection 62 is removed, like the projection62 shown in FIG. 11.

The window molding member 50 shown in FIGS. 19 and 20 can be producedessentially in the manner described with reference to FIG. 4. In thisconnection, there is shown in FIGS. 21 and 22 a preferred from of thefirst cutting station 27 for effecting the controlled removal of thematerial from the lip section 61. More particularly, the station 27 isarranged on or adjacent to the extrusion die 24, and includes a cuttermember 73 in the form of a tensioned heated wire which is supported by amovable frame 74 and which, by supplying an electric current, can beheated to a temperature above the softening point, preferably above themelting point of the synthetic resin material. The frame 74 is slidablyguided by elongate guide members 75, and connected with a reversibleservomotor 76 by means of a screw threaded rod 77. The servomotor 76 iscontrolled in accordance with the length of a core element 57 suppliedto the die, to displace the cutter member 73 in the directions M' and N'and to thus selectively remove the material of the projection 62 on thelip section 61.

When the cutter member 73 supplied with electric current is ultimatelyurged against the outer surface of the lip section 61, the material ofthe projection 62 is removed, as shown by the dotted line in FIG. 19,providing a smooth cut surface 62a without undesirable sharp edges.During the period in which the cutter member 73 formed of heated wireremoves the material of the projection 62, the cutter member 73 may bemoved in its longitudinal direction, in order to avoid scorching of thematerial by the heat of the wire 73 and the resultant deterioration inthe appearance. To this end, also, the surface of the cutting member 73may be coated with a material having a sufficient heat durability and anexcellent low frictional coefficient, such as polytetrafluoroethylene(PTFE). Use of the heated wire 73 heated above the softening point ofthe synthetic resin material is desirable, since the resistance to whichthe cutter member 73 is subjected during the removal of the material canbe substantially reduced. In particular, the heated wire 73 heated abovethe melting point of the synthetic resin material advantageouslyprovides the cut surface 62a with an excellent glazing. Furthermore, asshown in FIG. 21, the extruded body 25 is discharged from the die withsuch an orientation that the projection 62 on the lip section 61 isdirected downwardly. By this, the material removed from the lip section61 undergoes a descending motion by the gravity, and may be received inan appropriate container arranged below the cutting station, withoutrequiring the provision of a take-up device.

The window molding member 50 shown in FIGS. 19 and 20 is for awindshield plate on the front side of an automobile, so that theprojection 62 has been removed along the upper and corner portions toprevent undesirable side flow of the water across the front pillar.When, however, the molding member is to be arranged along the peripheryof the rear window, the projection 62' may be formed on the lip section60, as shown by the imaginary line in FIG. 20. The projection 62' may beremoved along the corner and side portions to realize a flush surface ofthe automobile, and may be present along the upper portion to preventflow of water from the roof onto the surface of the rear window and tothereby preserve a necessary rear sight in the rainy climate condition.

It is of course that various modifications may be made to thearrangement of the cutting member. For example, the cutting member maybe formed of a blade 78 with a curvature which coincides with that ofthe lip section 61, as shown in FIG. 23. The cutting member 78 may beformed with a coated layer of polytetrafluoroethylene (PTFE) or othersuitable material with a low frictional coefficient, to reduce theresistance during the removal of the synthetic resin material from thelip section 61, and to provide a smooth cut surface of the moldingmember. Instead of a linear motion of the cutting member toward and awayfrom the lip section 61, as in the previous embodiments, the cuttingmember may be mounted on a swing arm guided along an arcuate path.Furthermore, when it is desirable to arrange the servomotor or the likedrive means for the cutting member as far from the heat source aspossible, the drive means may be connected to the screw threaded rodindirectly, i.e. with a flexible shaft, or with a spline shaft combinedwith universal joints.

A further embodiment of the window molding member 50 is shown in FIG.24, which is similar to that explained with reference to FIGS. 19 and20, but in which the leg section 58 is provided with a side projection58c on its free end such that the window plate 51 is brought intoengagement with the molding member 50 between the lip section 61 and theside projection 58c. In this case also, the synthetic resin material isselectively removed from the lip section 61 in accordance with thelength of the core element supplied to the die.

From the foregoing description, it will be appreciated that the presentinvention provides a novel method of producing elongate molding membersfor automobiles, whereby the longitudinally variable cross-sectionalshape of the molding member can be readily obtained essentially based onextrusion molding technology, simply by removing a controlled amount ofthe synthetic resin material from a predetermined location of thecontinuous body after it has been extruded, and by subsequently cuttingthe continuous body into a predetermined length of the molding member.The present invention is advantageous in that all the process steps canbe carried out continuously, as contrasted with the conventionalinjection molding method, so that it is possible to produce the moldingmember with the desired, longitudinally variable cross-sectional shape,by means of a compact arrangement of the facility, and with a markedlyimproved productivity.

What is claimed is:
 1. A molding member for an automobile, said moldingmember being formed at least partly of a synthetic resin material, saidmolding member being a front window molding member which includes a legsection including at least one fin adapted to engage with a body panelof the automobile and a main body adapted to cover a gap formed betweena window plate and an automobile body panel, a lip section projecting inits cross-section from said main body and adapted to cover the outerperiphery of said window plate, and a ridge section projecting in itscross-section from said lip section for preventing flow of water acrossa side edge of said window plate, said molding member being produced bya method which comprises the steps of:(a) extruding the synthetic resinmaterial into an elongate continuous body with a substantially constantcross-section throughout the entire length thereof; (b) detecting anextruded length of the continuous body; (c) removing from saidcontinuous body a controlled amount of the synthetic resin material,synchronously with the extrusion of the synthetic resin material andimmediately after the continuous body has been extruded while it isstill soft and hot, such that the cross-section of said continuous bodyvaries in a longitudinal direction thereof, said controlled amount beingcontrolled in accordance with a detected length of the continuous bodydetected in step (b); and (d) subsequently cutting said continuous bodyinto a predetermined length of the molding member, wherein said moldingmember has an upper portion adapted to extend along the junction betweenan upper edge of said window plate and a roof panel of the automobile,wherein said lip section of said molding member, as extruded, has aprojection near a free end thereof, said projection forming said ridgesection which is adapted to bear against an outer surface of said windowplate, wherein said controlled amount of the synthetic resin material isremoved from said ridge section along said upper portion and whereinsaid lip section along said upper portion is oriented relative to saidleg section such that said free end is adapted to bear against saidsurface of said window plate.
 2. A molding member for an automobile,said molding member being formed at least partly of a synthetic resinmaterial, said molding member being a rear window molding member whichincludes a leg section including at least one fin adapted to engage witha body panel of the automobile and a main body adapted to cover a gapformed between a window plate and an automobile body panel, a lipsection projecting in its cross-section from said main body and adaptedto cover the outer periphery of said window plate, and a ridge sectionprojecting in its cross-section from said lip section for preventingflow of water onto said window plate, said molding member being producedby a method which comprises the steps of:(a) extruding the syntheticresin material into an elongate continuous body with a substantiallyconstant cross-section throughout the entire length thereof; (b)detecting an extruded length of the continuous body; (c) removing fromsaid continuous body a controlled amount of the synthetic resinmaterial, synchronously with the extrusion of the synthetic resinmaterial and immediately after the continuous body has been extrudedwhile it is still soft and hot, such that the cross-section of saidcontinuous body varies in a longitudinal direction thereof, saidcontrolled amount being controlled in accordance with a detected lengthof the continuous body detected in step (b); and (d) subsequentlycutting said continuous body into a predetermined length of the moldingmember, wherein said molding member has a side portion adapted to extendalong the junction between a side edge of said window plate and a rearpillar of the automobile, wherein said lip section of said moldingmember, as extruded, has a projection forming said ridge section,wherein said controlled amount of the synthetic resin material isremoved from said projection along said side portion, and wherein saidlip section along said side portion is oriented with respect to said legsection such that a free end of said lip section is adapted to bearagainst said surface of said window plate.
 3. A molding member for anautomobile, said molding member being formed at least partly of asynthetic resin material, said molding member being a front windowmolding member which includes a leg section including at least one finadapted to engage with a body panel of the automobile and a main bodyadapted to cover a gap formed between a window plate and an automobilebody panel, a lip section projecting in its cross-section from said mainbody and adapted to cover the outer periphery of said window plate, anda ridge section projecting in its cross-section from said lip sectionfor preventing flow of water across a side edge of said window plate,said molding member being produced by a method which comprises the stepsof:(a) extruding the synthetic resin material into an elongatecontinuous body with a substantially constant cross-section throughoutthe entire length thereof; (b) detecting an extruded length of thecontinuous body; (c) removing from said continuous body a controlledamount of the synthetic resin material, synchronously with the extrusionof the synthetic resin material, such that the cross-section of saidcontinuous body varies in a longitudinal direction thereof, saidcontrolled amount being controlled in accordance with a detected lengthof the continuous body detected in step (b); and (d) subsequentlycutting said continuous body into a predetermined length of the moldingmember, wherein said molding member has an upper portion adapted toextend along the junction between an upper edge of said window plate anda roof panel of the automobile, wherein said lip section of said moldingmember, as extruded, has a projection near a free end thereof, saidprojection forming said ridge section which is adapted to bear againstan outer surface of said window plate, wherein said controlled amount ofthe synthetic resin material is removed from said ridge section alongsaid upper portion and wherein said lip section along said upper portionis oriented relative to said leg section such that said free end isadapted to bear against said surface of said window plate.
 4. A moldingmember for an automobile, said molding member being formed at leastpartly of a synthetic resin material, said molding being a front windowmolding member which includes a leg section including at least one finadapted to engage with a body panel of the automobile and a main bodyadapted to cover a gap formed between a window plate and an automobilebody panel, a lip section projecting in its cross-section from said mainbody and adapted to cover the outer periphery of said window plate, anda ridge section projecting in its cross-section from said lip sectionfor preventing flow of water across a side edge of said window plate,said molding member being produced by a method which comprises the stepsof:(a) continuously supplying a core element to an extrusion die andco-extruding said synthetic resin material about said core element intoan elongate continuous body with a substantially constant cross-sectionthroughout the entire length thereof; (b) detecting a supplied length ofsaid core element; (c) removing from said continuous body a controlledamount of the synthetic resin material, synchronously with the extrusionof the synthetic resin material, such that the cross-section of saidcontinuous body varies in a longitudinal direction thereof, saidcontrolled amount being controlled in accordance with a supplied lengthof said core element detected in step (b); and (d) subsequently cuttingsaid continuous body into a predetermined length of the molding member,wherein said molding member has an upper portion adapted to extend alongthe junction between an upper edge of said window plate and a roof panelof the automobile, wherein said lip section of said molding member, asextruded, has a projection near a free end thereof, said projectionforming said ridge section which is adapted to bear against an outersurface of said window plate, wherein said controlled amount of thesynthetic resin material is removed from said ridge section along saidupper portion and wherein said lip section along said upper portion isoriented relative to said leg section such that said free end is adaptedto bear against said surface of said window plate.
 5. A molding memberfor an automobile, said molding member being formed at least partly of asynthetic resin material, said molding member being a rear windowmolding member which includes a leg section including at least one finadapted to engage with a body panel of the automobile and a main bodyadapted to cover a gap formed between a window plate and an automobilebody panel, a lip section projecting in its cross-section from said mainbody and adapted to cover the outer periphery of said window plate, anda ridge section projecting in its cross-section from said lip sectionfor preventing flow of water onto said window plate, said molding memberbeing produced by a method which comprises the steps of:(a) extrudingthe synthetic resin material into an elongate continuous body with asubstantially constant cross-section throughout the entire lengththereof; (b) detecting an extruded length of the continuous body; (c)removing from said continuous body a controlled amount of the syntheticresin material, synchronously with the extrusion of the synthetic resinmaterial, such that the cross-section of said continuous body varies ina longitudinal direction thereof, said controlled amount beingcontrolled in accordance with a detected length of the continuous bodydetected in step (b); and (d) subsequently cutting said continuous bodyinto a predetermined length of the molding member, wherein said moldingmember has a side portion adapted to extend along the junction between aside edge of said window plate and a rear pillar of the automobile,wherein said lip section of said molding member, as extruded, has aprojection forming said ridge section, wherein said controlled amount ofthe synthetic resin material is removed from said projection along saidside portion and wherein said lip section along said side portion isoriented with respect to said leg section such that a free end of saidlip section is adapted to bear against said surface of said windowplate.
 6. A molding member for an automobile, said molding member beingformed at least partly of a synthetic resin material, said molding beinga rear window molding member which includes a leg section including atleast one fin adapted to engage with a body panel of the autombile and amain body adapted to cover a gap formed between a window plate and anautomobile body panel, a lip section projecting in its cross-sectionfrom said main body and adapted to cover the outer periphery of saidwindow plate, and a ridge section projecting in its cross-section fromsaid lip section for preventing flow of water onto said window plate,said molding member being produced by a method which comprises the stepsof:(a) continuously supplying a core element to an extrusion die andco-extruding said synthetic resin material about said core element intoan elongate continuous body with a substantially constant cross-sectionthroughout the entire length thereof; (b) detecting a supplied length ofsaid core element; (c) removing from said ridge section of saidcontinuous body a controlled amount of the synthetic resin material,synchronously with the extrusion of the synthetic resin material, suchthat the cross-section of said continuous body varies in a longitudinaldirection thereof, said controlled amount being controlled in accordancewith a supplied length of said core element detected in step (b); and(d) subsequently cutting said continuous body into a predeterminedlength of the molding member, wherein said molding member has a sideportion adapted to extend along the junction between a side edge of saidwindow plate and a rear pillar of the automobile, wherein said lipsection of said molding member, as extruded, has a projection formingsaid ridge section, wherein said controlled amount of the syntheticresin material is removed from said projection along said side portionand wherein said lip section along said side portion is oriented withrespect to said leg section such that a free end of said lip section isadapted to bear against said surface of said window plate.